Edge contourable diaper

ABSTRACT

A contourable diaper including, a pleated fluid pervious cover sheet and a pleated fluid impervious back sheet secured to each other adjacent the lateral and longitudinal edges of the diaper. An absorbent pad is positioned intermediate the cover and back sheets and extends at least throughout the crotch region of the diaper. The diaper is transformed from a generally planar and rectangular shape to an arcuate configuration responsive to longitudinal expansion of the cover and back sheets, and the longitudinal edges of the sheets bow inwardly in at least the central region of the diaper to generally conform to the contour of an infant&#39;&#39;s body.

Unlted States Patent -1 1 [111 3,776,233

Schaar 1 Dec. 4, 1973 [54] EDGE CONTOURABLE DIAPER 3,196,874 7/1965Hrubecky 128/287 3,572,342 3/1971 [75] Inventor: Charles H. Schaar, LakeZurich, Ill. 3 610 244 10/1971 [73] Assigneez Colgate-Palmolive Compan N2,788,786 4/1957 Dexter 128/287 York, N.Y. Primary ExaminerCharles F.Rosenbaum [22] Flledi May 17, 1971 Attorney-Powell L. Sprunger 21] i A1.No.: 144032 pp v 57] ABSTRACT A contourable diaper including, apleated fluid pervi- [52] U.S. Cl. 128/287 ous cover Sheet and a leatedfluid im ervious back 51 Int (:1 A6lf 13/16 p p 58 4 286 287 sheetsecured to each other adjacent the lateral and 1 le o are l glongitudinal edges of the diaper. An absorbent pad is positionedintermediate the cover and back sheets and extends at least throughoutthe crotch region of the [56] References C'ted diaper. The diaper istransformed from a generally UNITED STATES PATENTS planar andrectangular shape to an arcuate configura- 2,910,982 11/1959 Woodward128/284 tion responsive to longitudinal expansion of the cover 3,030,9564/1962 Nichols 128/284 and back sheets, and the longitudinal edges Ofthe 3,036,573 5/ 1962 Volgtma 128/287 X sheets bow inwardly in at leastthe central region of 3,306,293 2/1967 Marder et a1. 128/284 the diaperto generally conform to the Contour of an 3,322,122 5/1967 Daniel128/284 infanvs bod 3,599,640 8/1971 Larson.... 128/286 3,636,952 1/1972George 128/287 6 Claims, 11 Drawing Figures 2 I g )2 232 228 j 228- t ii -1 g 7 A f fl ,v 222 EDGE CONTOURABLE DIAPER BACKGROUND OF THEINVENTION of the body in the crotch region and about the infants legs.This problem has been more pronounced in disposable diapers than inconventional cloth diapers, since the former are less pliable and do notas readily adapt to the shape of the body. Accordingly, when thestandard flat rectangular disposable diapers are placed on the infant,they assume a bulky configuration in the crotch region of the baby,resulting in irritation and discomfort. Additionally,"the longitudinaledges of such diapers do not readily seal against the babys body in thecrotch region and about the legs, and gaps develop through which fluidmay escape.

To alleviate this problem, an expandable diaper is disclosed in mycopending application Expandable Article Ser. No. 128,267, filed Mar.26, 1971, continuation-in-part of application Ser. No. 41,377, filed May28, 1970 and now abandoned. However, it is desirable to obtain animproved fit in such diapers about the contour of the infants body, andprovide a flat diaper which readily conforms to the body.

SUMMARY OF THE INVENTION A principal feature of the present invention isthe provision of a diaper of simplified construction which closelyconforms to the contour of an infants body.

The diaper of the invention has a pleated fluid pervious cover sheet,and a pleated fluid impervious back sheet which is secured to the coversheet adjacent the lateral and longitudinal edges of the diaper, withthe securedsheets having a generally rectangular shape. An absorbent padis positioned intermediate the cover and back sheets and extends atleast throughout the crotch region of the diaper.

A feature of the invention is that the diaper is transformedfrom agenerally planar to an arcuate shape responsive to longitudinalexpansion of the back and cover sheets.

Another feature of the invention is that the longitudinal edges of thesheets bow inwardly in at least the central region of the diaper forconformation of the edges to the body's contour.

In one embodiment of the invention the diaper has expandable pad meanspositioned between the sheets, and includes a pair of longitudinal flapsadhered to the cover sheet in the central region of the diaper.

A further feature is that the flaps have arcuate edges extendinglongitudinally along the diaper for improved conformation of theexpandable diaper to the body contour.

Further features will become more fully apparent in the followingdescription of the embodiments of this invention and from the appendedclaims.

DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. 1 is a plan view partly broken away of the contourable diaper ofthe present invention;

FIG. 2 is a plan view from the backside of the diaper of FIG. 1;

FIG. 3 is a cross sectional view taken substantiallyas indicated alongthe line 3-3 of FIG. 1;

FIG. 4 is a perspective view partly broken away of the diaper of FIG. 1with the cover and back sheets in an expanded configuration;

FIG. 5 is a plan view partly broken away of another embodiment of thepresent invention having an elongated absorbent pad;

FIG. 6 is a perspective view partly broken away of the diaper of FIG. 5with the cover and back sheets in an expanded configuration;

FIG. 7 is a perspective view of another embodiment of the presentinvention;

FIG. 8 is a cross sectional view taken substantially as indicated alongthe line 88 of FIG. 7;

FIG. 9 is a cross sectional view taken substantially as indicated alongthe line 9-9 of FIG. 7;

FIG. 10 is a plan view of the diaper of FIG. 7 in a partly expandedconfiguration; and

FIG. 11 is a perspective view partly brokenaway of the diaper of FIG. 7in an expanded configuration.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIGS. 1-3, adiaper designated generally 20 is shown having a fluid pervious coversheet 22, such as a nonwoven material, a fluid impervious back sheet 24,and an absorbent pad 26 positioned intermediate the sheets 22 and 24.The back sheet 24 is secured to the cover sheet 22 adjacent the lateraland longitudinal edges of the diaper .28 and 30, respectively, to forman envelope for retaining the pad 26 in position, and provide the diaper20 .with a generally planar and rectangular shape.

The back sheet 24 has a plurality of pleats 32 extending laterallyacross the diapers 20 in its central region, or the region substantiallymidway between the lateral edges 28, and the pleats 32 are tacked, suchas byheat seals or adhesive spots 34, adjacent the. longitudinal edges30 of the diaper 20. Similarly, the cover sheet22 has a laterallyextending pleat 36 in the central region of the diaper 20. The absorbentpad 26 has a generally rectangular shape and extends substantiallybetween the lateral and longitudinal edges 28 and 30 of the diaper 20.

As illustrated in FIG. 4, prior to application of the diaper 20 to aninfant, the cover and back sheets 22 and 24 are longitudinally stretchedby grasping and pulling .thediaper adjacent the lateral edges 28. If theabsorbent pad 26 is made from a relatively strongmaterial, such ascellulose wadding, then the lateral edges of the pad 26 are preferablyspaced slightly from the edges of diaper 28, as shown in FIG. 3, inorder that the lateral edge of the diaper may readily be grasped withoutgrasping the lateral edges of the pad for stretching the diaper.However, if the pad 26 is made from a relatively soft material, such aswood fluff, the lateral edges of the pad may extend to the lateral edgesof the diaper,since such pads may be ruptured during expansion of thediaper without affecting its absorptive capacity.

Since the cover and back sheet pleats 36 and 32 are secured at thelongitudinal edges 30 of the diaper 20,

the longitudinal edges 30 remain a fixed length during stretching of thesheets. However, the cover and back sheet pleats 36 and 32 unfoldintermediate the longitudinal edges 30 responsive to expansion of thediaper, and the longitudinal distance between the diaper lateral edges28 through the center of the diaper increases relative to the length ofthe longitudinal edges 30 after the diaperis expanded. Accordingly, thegenerally planar diaper, as shown in FIGS. 1,3, is transformed to anarcuate configuration, and the longitudinal diaper edges 30 bow inwardlyin thecentral region of the diaper adjacent the back sheet seals 34.Thus, the lateral diaper edges 28 remain of constant length duringexpansion of the diaper for securing the diaper about the waistline ofthe infant, while the distance laterally across the diaper in thecentral region reduces, in order that the edges 30 have a contour whichgenerally conforms to the contour of the infants body about the legsfrom the crotch region to the babys waistline. Accordingly, when theexpanded diaper is placed on the infant, the longitudinal diaper edges30 form a close sealing contact with the babys body to prevent theescape of fluids. Moreover, the backsheet 24 of the expanded diaperassumes a pouch-like configuration to prevent interference of bulk inthe diaper with movement of the infants legs and to provide afluid-retention chamber for body wastes.

Another embodiment of the invention is illustrated in FIGS. 5 and 6, inwhich similar reference numerals are increased by 100 from those inFIGS. 1-4. In this embodiment, the absorbent pad 126 has an elongatedshape longitudinally along the diaper. The pad 126 has an enlargedcentral portion 160 in the crotch region of the diaper, and a pair oftapered end portions 162 which extend longitudinally from the centralportion 160 toward the lateral diaper edges 128. The pad 162 is securedto the back sheet 124 by means 161, such as adhesive, to prevent the padfrom sliding within the cover and back sheets 122 and 124. As shown inFIG. 6, the cover and back sheets of the diaper 120 expand in a similarfashion to those in the diaper 20 of FIGS. 1-4, and the diaper istransformed from a generally planar to arcuate configuration, with thelongitudinal diaper edges 130 bowing inwardly in the central region ofthe diaper. However, the elongated and tapered shape of the absorbentpad 126 additionally causes the back sheet 124 to assume a tray-likeshape, such that the pad 126 is nested between longitudinally extendingfolds 163 in the back sheet 124. Thus the expanded back sheet 124 formsa pair of upraised side portions 164 which remain relatively closelyspaced to the cover sheet 122, while the pad 126 is positioned in acentral recessed portion of the back sheet which extends longitudinallyin the diaper between the folds 163. Since the pad 126 does not extendthe full lateral distance of the diaper 120 between the edges 130, thefolds 163 of the back sheet 124 partially overlie the pad 126, and thelongitudinal diaper edges 130 are permitted to move closely together inthe crotch region of the diaper. Additionally, the tray-like shapeformed by the back sheet due to the shape of the pad 126 forms aconvenient pouch for the collection of waste from the body.

Another embodiment of the invention is illustrated in FIGS. 7-11, and asshown in FIGS. 7-9 the diaper 220 has a fluid impervious back sheet 224secured to a fluid impervious cover sheet 222 adjacent the lateral edges228 of the diaper. The back sheet 224 has a plurality of laterallyextending pleats 232 in the central region of the diaper, and the coversheet 222 has a laterally ex- 6 222 and 224. The pad means 280 has aplurality of absorbent pads 282 which havestaggered portions 284 in thecentral region of the diaper. The staggered portions 284 are securedtogether in the central region of the diaper, such as by adhesive, at apair of laterally spaced positions 286.

The diaper 220 has a pair of longitudinally extending flaps 290 whichpartially overlie lateral portions of the cover sheet 222, and the flaps290 are adhered to the cover sheet 222 at a pair of laterally spacedpositions 292 in the central region of the diaper to retain the flaps290 in position. The flaps 290 have arcuate edges extendinglongitudinally between the lateral edges 228 of the diaper 220, suchthat the flaps are more narrow in the central region of the diaper thanat the diaper lateral edges 228.

One manner in which the arcuate shaped edges may be formed is describedas follows. First, a lateral cut is made on each longitudinal side ofthe pad means adjacent the center of the diaper, with the cut on eachside entending inwardly for some distance from the longitudinal edge ofthe pad means. Next, the sides of the pad means are overlapped at themargin of its longitudinal edges, such that a pair of flaps is foldedover on each side of the pad means along fold lines extending from theinner edge of the cut to adjacent the comers of the pad means. Finally,the cover sheet 222, and then the back sheet, are folded over the foldlines in the pad means and secured in place. Accordingly, the fold linesin the pad means primarily define the arcuate shape of the flap edges294.

As illustrated in FIG. 10, the diaper 220 is expanded by grasping thelateral edges 228, including the edges of the cover sheet 222, the backsheet 224 and the pad means 280, and by stretching the diaperlongitudinally, as indicated by the arrows in the drawing. Duringexpansion the pleats of the cover and back sheets 236 and 232 unfold,and the pad means 280 forms a bulked configuration, as described in mycopending application Expandable Article, which has been previouslyreferred to in the specification. As shown in FIG. 11, when the diaper220 is expanded the arcuate shape of the flap edges 294 is furtherenhanced, and the flap edges 294 flare outwardly from the central regionof the diaper to the lateral diaper edges 228. The flap edges 294 remainrelatively closely spaced in the diaper crotch region, while they becomewidely spaced along the lateral diaper edges 228. Thus, the flap edges294 in the expanded diaper generally conform to the contour of theinfants body to provide a close sealing contact of the diaper with thebody and prevent the escape of fluids.

The foregoing detailed description is given for clearness ofunderstanding only, and no unnecessary limitations should be understoodtherefrom, as modifications will be obvious to those skilled in the art.

I claim:

1. A contourable diaper comprising:

a fluid pervious cover sheet having at least one laterally extendingpleat in the central region of the dia- P a fluid impervious back sheetsecured to said cover sheet adjacent the lateral and longitudinal edgesof said diaper, with said secured sheets having a generally rectangularshape, said back sheet having at least one pleat in the central regionof the diaper extending laterally across the back sheet, with the pleatsin the back and cover sheets being tacked adjacent the longitudinaledges of the diaper; and

an absorbent pad positioned intermediate said cover and back sheets andextending at least throughout the crotch region of the diaper, saiddiaper transforming from a generally planar shape to an arcuateconfiguration responsive to longitudinal expansion of said sheets, withthe longitudinal edges of said sheets bowing inwardly in the centralregion of the diaper to generally conform to the contour of an infantsbody.

2. The contourable diaper of claim 1 wherein said absorbent pad isgenerally rectangular and extends substantially between the lateral andlongitudinal edges of the diaper.

3. The contourable diaper of claim 1 wherein said absorbent pad iselongated longitudinally along said diaper, said pad havingan enlargedcentral portion in the crotch region of the diaper and a pair of taperedend portions extending longitudinally from said central portion towardthe lateral edges of the diaper.

4. In an expandable diaper having an expandable back sheet, anexpandable cover sheet, and expandable pad means positioned between saidsheets, including a plurality of absorbent pads having staggeredportions in the central region of the diaper, with said staggeredportions being secured together in at least a pair of spaced positionslaterally across the diaper, said diaper having a pair of longitudinalflaps adhered to said cover sheet in the central region of the diaper,the improvement in which comprises, said flaps having arcuate edgesextending longitudinally along the diaper, with said flaps narrowing inthe central region of the diaper, whereby said flap edges generallyconform to the contour of an infants body after expansion of saiddiaper.

5. in a longitudinally expandable diaper having an ab sorbent pad, acover sheet, a back sheet secured to said cover sheet with said padbeing positioned intermediate the cover and back sheets, and a pair oflongitudinal flaps at least partially overlying and secured to saidcover sheet, the improvement in which comprises, said flaps havingarcuate edges extending longitudinally obtain said arcuate shaped edgesin the diaper flaps.

. UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,776,233 Dated December 4, 1.973

lnventofls) Charles H. Sohaar It is certified that error appears iii theabove-idehtified patent and that said Letters Patent are herebycorrected as shown below:

Column 4,- line 19, change"180" to -280-- Signed and sealed this 16thday of April 197R.

(SEAL) Attest:

EDWARD M.FLETCHER,JR C MARSHALL DANN I Attesting Officer Commissioner ofPatents USCOMM-DC scan-m9 i U. 5 GOVERNMENT PRIN ING OFFICE I," O-8-3SlFOR M FO-1050 (10-69)

1. A contourable diaper comprising: a fluid pervious cover sheet havingat least one laterally extending pleat in the central region of thediaper; a fluid impervious back sheet secured to said cover sheetadjacent the lateral and longitudinal edges of said diaper, with saidsecured sheets having a generally rectangular shape, said back sheethaving at least one pleat in the central region of the diaper extendinglaterally across the back sheet, with the pleats in the back and coversheets being tacked adjacent the longitudinal edges of the diaper; andan absorbent pad positioned intermediate said cover and back sheets andextending at least throughout the crotch region of the diaper, saiddiaper transforming from a generally planar shape to an arcuateconfiguration responsive to longitudinal expansion of said sheets, withthe longitudinal edges of said sheets bowing inwardly in the centralregion of the diaper to generally conform to the contour of an infant''sbody.
 2. The contourable diaper of claim 1 wherein said absorbent pad isgenerally rectangular and extends substantially between the lateral andlongitudinal edges of the diaper.
 3. The contourable diaper of claim 1wherein said absorbent pad is elongated longitudinally along saiddiaper, said pad having an enlarged central portion in the crotch regionof the diaper and a pair of tapered end portions extendinglongitudinally from said central portion toward the lateral edges of thediaper.
 4. In an expandable diaper having an expandable back sheet, anexpandable cover sheet, and expandable pad means positioned between saidsheets, includIng a plurality of absorbent pads having staggeredportions in the central region of the diaper, with said staggeredportions being secured together in at least a pair of spaced positionslaterally across the diaper, said diaper having a pair of longitudinalflaps adhered to said cover sheet in the central region of the diaper,the improvement in which comprises, said flaps having arcuate edgesextending longitudinally along the diaper, with said flaps narrowing inthe central region of the diaper, whereby said flap edges generallyconform to the contour of an infant''s body after expansion of saiddiaper.
 5. In a longitudinally expandable diaper having an absorbentpad, a cover sheet, a back sheet secured to said cover sheet with saidpad being positioned intermediate the cover and back sheets, and a pairof longitudinal flaps at least partially overlying and secured to saidcover sheet, the improvement in which comprises, said flaps havingarcuate edges extending longitudinally along the diaper, with said flapsnarrowing in the central region of the diaper, whereby said flap edgesgenerally conform to the contour of an infant''s body.
 6. The diaper ofclaim 5 wherein said absorbent pad is overlapped at the margin of itslongitudinal edges to obtain said arcuate shaped edges in the diaperflaps.